Case study: enhancing safety and efficiency in surface preparation on the transocean leader
In 2012, the Transocean Leader, a prominent offshore drilling rig, required comprehensive maintenance in its cementing room, encompassing diesel engines, piping, tanks, and structural frames. The project aimed to degrease, high-pressure wash, mechanically pretreat corroded areas, perform spot painting on pretreated sections, and repaint the entire unit, transitioning from orange to blue.
Challenges
The maintenance team faced several obstacles:
- Surface contaminants: The presence of grease, oil, and other impurities necessitated thorough cleaning.
- Confined spaces: The cramped environment, coupled with intricate wiring and instruments, rendered traditional blasting methods impractical.
Considered solutions
The team evaluated multiple surface preparation methods:
- Spot sandblasting/vacuum blasting: Deemed unsuitable due to space constraints and potential equipment interference.
- Mechanical pretreatment with flap discs/needle guns: Posed risks of hot sparks and required extensive safety measures.
- Ultra High-Pressure Water Jetting (2000 bar): Presented challenges in confined spaces and required significant setup.
- Mechanical Pretreatment with Safety Tools Allmet ATEX-Tools: Offered a cold work solution with minimal setup and enhanced safety features.
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The chosen solution:
The team selected mechanical pretreatment using Safety Tools Allmet’s ATEX-certified grinding tools, specifically the A-0010 “Rough Boy” and A-0008 “Big Papa” models. This decision was based on several advantages:
- Safety: The tools operate without emitting hot sparks, eliminating the need for hot work permits and reducing fire hazards.
- Dust control: Low RPM operation minimizes airborne dust, enhancing visibility and reducing respiratory risks.
- Surface cleanliness: The rotary files achieved a cleanliness level of ST 3 / Sa 2 ½, meeting industry standards.
- Surface roughness: The treated surfaces exhibited a roughness of 50-75 microns, aligning with NORSOK M-501 requirements.
- Productivity: The tools required minimal setup and demonstrated higher efficiency compared to traditional methods like needle guns or flap discs.
Outcomes
The implementation of Safety Tools Allmet’s grinding tools yielded notable benefits:
- Operational efficiency: Simplified setup with only compressed air hoses led to faster completion times. The robust design ensured minimal wear, allowing the tools to be reused for multiple projects.
- Cost-effectiveness: Enhanced productivity and durable tool construction resulted in significant cost savings over time.
- Quality assurance: The tools provided surfaces that met cleanliness and roughness standards, ensuring optimal adhesion for subsequent paint applications.
- Health and safety: Low vibration levels reduced operator fatigue, and the absence of hot sparks and airborne dust minimized health risks.
Operator feedback
Operators reported positive experiences, noting the equipment’s reliability, low noise levels, and efficiency in removing paint and rust without requiring excessive force.
Conclusion
The use of Safety Tools Allmet’s ATEX-certified grinding tools on the Transocean Leader exemplifies how innovative equipment can overcome challenging maintenance scenarios. By prioritizing safety, efficiency, and quality, these tools offer a superior alternative to traditional mechanical pretreatment methods.
Explore our solutions
- Surface treatment in ATEX Zones: Safely prepare surfaces in explosive environments with our ATEX-certified tools, ensuring compliance and optimal coating adhesion.
- Spot repair in ATEX Zones: Address localized corrosion efficiently using our specialized equipment, designed for safe operation within ATEX environments.
- Corrosion removal in ATEX Zones: Effectively remove corrosion without the risks associated with traditional methods, maintaining structural integrity.
- Paint and coating removal in ATEX Zones: Strip old paints and coatings safely in hazardous areas with our compliant tools, facilitating necessary maintenance while adhering to safety standards.
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Ensure the safety and reliability of your assets with Allmet Safety Tools’ expert services. Contact us to discuss how our solutions can meet your maintenance and repair needs.